PG300/350 PEDESTAL GRINDER MANUAL

Transcription

1 A.C.N A.B.N BROBO WALDOWN (AUST) PTY. LTD Williams Rd, Dandenong, 3175 PO BOX 4274 Dandenong Sth, 3164 Victoria, AUSTRALIA. Tel: info@brobo.com.au Fax: Website: Certified System Quality ISO 9001 PRODUCT AND MAINTENANCE MANUAL PG300/350 PEDESTAL GRINDER MANUAL YOUR BROBO WALDOWN DISTRIBUTOR IS: Precision Drilling Machines Tapping Machines Multi Head Drills Tool Grinders Machine Vices Special Production Equipment Accessories Pedestal Grinders Metal Cutting Saws

2 OPERATING MANUAL FOR PG300/350 PEDESTAL GRINDER TECHNICAL SPECIFICATION i CHAPTER 1: Installation of the Machine 1.1 Unpacking and Handling the Machine Parts Checklist Minimum Requirements Anchoring the Grinder Unit Connection to Power Source 3 CHAPTER 2: Safety and Accident Prevention 2.1 Operation of the Machine Noise Level Power Supply General Requirements Advice for the Operator Machine Safety Devices Reference Standards 6 CHAPTER 3: Main Functions and Operation of the Machine Safety Eye Shields Emergency Stop Button Toolrest Water Pot Preparation for Operation Operation Recommendations 8 CHAPTER 4: Drawings, Layouts, Assembly and Spare Parts Assembly Drawing (1 of 3) Assembly Drawing (2 of 3) Assembly Drawing (3 of 3) Miscellaneous Part List 12 CHAPTER 5: Maintenance and Selection of Consumables 5.1 Role of the Operator Maintenance Requirements General Maintenance of Functioning Components 13 CHAPTER 6: Troubleshoot 6.1 Troubleshooting For Blade and Cutting Problems 15 APPENDIX i. Hazard/Risk Assessment 16 ii. Warranty 17

3 TECHNICAL SPECIFICATION MACHINE SPECIFICATION MOTOR RATING (kw / Hz / V / PH) WHEEL/BELT SPECIFICATIONS WHEEL CENTRE, WHEEL CENTRE HEIGHT & WHEEL SPEEDS PG300 ( ) 2.2kW 50Hz, 415V, 3PH 300mm x 50mm width x 31.75mm bore (1¼ ) V-Belt B Section 70mm 608mm, R937mm & 2050/2400 RPMs PG350 ( ) 2.2kW 50Hz, 415V, 3PH 300mm x 50mm width x 31.75mm bore (1¼ ) V-Belt B Section 70mm 608mm, R937mm & 1770/2070 RPMs Packed Weight: PG kg PG kg

4 CHAPTER 1 - Installation of the Machine 1.1 Unpacking and Handling the Machine Upon receiving the Brobo Waldown PG300/350 Pedestal Grinder, the machine should be sitting in the upright position before opening the packaging (See Figure 1). Carefully remove the packaging surrounding the pedestal grinder. Position the grinder to the desired location, ensuring that a power outlet is available and within reach of the grinder power cord. Loosen the base bolts restraining the grinder and sling a harness around the body of the unit, while being mindful that equal weight distribution is required to prevent it from tipping. Raise the pedestal grinder, slide the pallet away from the machine and re-lower the grinder to the final location. Prior to powering up the grinder, place the desired wheel/buff mop onto the machine spindles. Note that if the bore sizes on the grinding wheels and/or buffering mops do not fit the spindle, taper adapters and buff adapters are readily available for purchase from most hardware and tool outlets. Once the wheels/buffs are securely fasten to the machine, connect the grinder to the mains electrical supply and power up the machine. Figure 1. Shipping of Grinder Unit PLEASE OBSERVE AND FOLLOW THE INSTALLATION INTRUCTIONS ON PAGE 2 1

5 1.2 Parts Checklist Along with the grinder unit, check that the following accessories, packed "loose", are included as follows: A. ACCESSORIES i. 1 Operation Manual 1.3 Minimum Requirements For the machine to function correctly, the room in which the grinder unit is to be installed must be in the vicinity of, and satisfy the following conditions: 240/415V Power Supply Ambient Temperature: From -10 to + 50 degrees C. Relative Humidity: Not more than 90%. Lighting: More than 500 LUX.!!!! WARNING OPERATING VOLTAGE VARIATION The pedestal grinder unit has an inbuilt safety electrical system to protect it against voltage variations. However, for the machine to operate efficiently, ensure that the grinder operates within ±10% limits of the recommended voltage on the motor. 1.4 Anchoring the Grinder Unit Prior to anchoring the grinder unit, take into considerations the requirements mentioned in Section 1.3 and Section 2.2, and other aspects regarding the usage of the machine such as accessibility to grinder parts and safe access for the operator. FLOOR MOUNTING Figure 2. Anchoring Hole Location 2

6 1.5 Connection to Power Source Before connecting the machine to the power supply, check that the socket is not connected in series with other machines. This condition is critical for the ideal operation of the drill (Referring to Figure 3 for wiring of 4-CORE power supply cable from the machine to a power plug. Check that the spindle rotary direction and change the phasing if required; clockwise rotation observing top-down on top of the motor pulley.) Note that single-phase machines are supplied in Australia with 15-amp plug). Furthermore, ensure that all the electrical leads and cables (including supply leads) are well maintained and should be immediately replaced if severed, sliced or damaged in any manner. Figure 3. Connection for 4-CORE Wire System with Neutral To connect the machine to the power supply, proceed as follows: 1) Insert the power plug into the socket, while ensuring that the mains voltage is compatible for which the grinder is operating at. VOLTAGE MAIN VOLTAGE 415/240V 3 PH 240V 2) Inspect that the grinder unit set to OFF position. 3) To prepare the machine for operation, release the STOP/EMERGENCY STOP button by twisting the red mushroom button. To activate the drill, engage the green START button. 4) If all of the above procedures have been carried out correctly, the grinder should now be operational The Brobo Waldown PG300/350 Pedestal Grinder is now ready for use. Chapter 3 provides a detailed description of the various functional features of the grinder and its operating cycle. 3

7 CHAPTER 2 - Safety and Accident Prevention The Brobo Waldown PG300/350 Pedestal Grinder has been designed and manufactured in accordance to Australian Standards. It is HIGHLY RECOMMENDED that the instructions and warnings contained in this chapter be carefully followed for correct usage of the machine. 2.1 Operation of the Machine The Brobo Waldown PG300/350 Pedestal Grinder is specifically design for grinding of various ferrous metal sections. This machine involves high-speed revolutions; therefore extreme caution is required when operating the device. The employer is responsible for instructing the personnel who, in turn, are obliged to inform the operator of any accident risks, safety devices, noise emission and accident prevention regulations provided for by national and international laws governing the use of the machine. The operator must be perfectly aware of the position and functions of all the machine s controls. All those concerned must strictly adhere to ALL instructions, warnings and accident prevention standards in this manual. The following definitions are those provided for by the EEC DIRECTIVE ON MACHINERY No. 98/37/CE: Danger Zone - any zone in and/or around a machine in which the presence of a person constitutes a risk for the safety and health of that person. Person Exposed - any person finding him or herself, either completely or partly in a danger zone. Operator - the person or persons given the responsibility of installing, operating, adjusting, maintaining, cleaning, repairing and transporting the machine.!!!! WARNING UNAUTHORISED MODIFICATIONS/REPLACEMENTS/USE The manufacturer declines any responsibility whatsoever, either civil of criminal, in the case of unauthorised interference or replacement of one or more parts or assemblies on the machine, or if accessories, tools and consumable materials are used that are different from those recommended by the manufacturer himself or if the machine is inserted in a plant system and its proper function is altered Noise Level The noise level of an idling grinder unit has been measured to be below 85 dba. This complies with the Australian Occupational Health and Safety (Noise) Regulations Please note that peak impulse noise levels will be experienced due to variables including drill characteristics, type, and condition. This will also vary accordingly depending on the size and type of sample being drilled. Under these circumstances, management should make available to the operator(s) the appropriate hearing protection equipment as prescribed under the above stated act. 4

8 2.1.2 Power Supply The 415/240V power supply requirements for this machine are of a high level and unauthorised interference and or inadequate maintenance could result in a situation that could put the operator at risk. A qualified electrical engineer should be assigned to maintain and repair the system. 2.2 General Requirements Lighting Insufficient lighting during the operation of the drill unit would constitute a safety hazard for the people concerned. For this reason, the user of the machine must provide adequate lighting in the working area to eliminate areas in shadow, whilst also preventing dazzling illumination sources (reference standard ISO Lighting of Indoor Workplaces ). Connections Check that the power supply cables, compressed air supply and/or coolant system complies with, and are operating within the acceptable range of the drill capabilities. Faulty, damaged or worn components must be replaced immediately. Earthing Systems The installation of the earthing system must comply with the requirements stated in the IEC Standards Part 195: Earthing and Protection Against Electric Shocks Advice for the Operator Protective eyewear or goggles must be worn at all times while attending and operating the grinder unit. Ensure that hands and arms are kept clear of the working zone when the machine is operating. Do not wear oversize clothing with long sleeves and oversize gloves, bracelets, necklaces or any other loose object that may become entangled in the machine s tooling bit during drilling. Long hair must be tied back or placed in a hair net. Always disconnect the power supply to the machine before carrying out any maintenance work or adjustments. This includes cases of abnormal operations of the machine. Always keep the workplace area as clean as possible. Remove equipment, tools or any other objects from the grinding zone. Support the work piece on both sides 5 of the machine to prevent it falling or jamming during the grinding cycle. 5

9 Always turn off the machine before carrying out any repair work. Consult the Brobo Waldown Engineering Department in the country in which the machine was initially purchased. 2.4 Machine Safety Devices This product and maintenance manual is not purely intended as a guide for the usage, operation and maintenance of the grinder unit in a strictly production environment; it is instead an instrument to providing information on how to use the machine correctly and safely. The following standards listed in section 2.4.1, which are applicable to the Brobo Waldown PG300/350 Pedestal Grinder, are those specified by the EEC Committee that governs safety of machinery, health and safety at work, personal protection and safeguarding of the work environment. In addition, the saw also complies with the Australian Standards regarding the safeguarding and general requirements for electrical equipment Reference Standards MACHINE SAFETY EEC Directive No. 98/37/CE - Machines Directive EEC Directive No. 91/368-94/68 - Amends sections of EEC Directive No. 98/37/CE relating to machine safety EEC Directive No. 73/23 - Low Voltage Directive AS Safeguarding of Machinery HEALTH AND SAFETY AT WORK AS General Requirements for Electrical Equipment Operational Health and Safety (OHS) / Compliance References EEC Directive No. 80/1107; 83/477; 86/188; 88/188; 88/642 - Protection of workers against risks caused by exposure to physical, chemical and biological agents in workplace EEC Directive No. 73/23 and Special EEC Directives No. 89/654; 89/655 - Improvements in health and safety at work 6

10 CHAPTER 3 - Main Functions and Operation of the Machine KEY: 1. Safety Eye Shields 2. Emergency STOP Button 3. Toolrest 4. Water Pot Safety Eye Shields The reinforced glass safety eye shield serves to protect the user from any debris and particles that might be dislodged from the grinding process. The bracket mountings also allow the user to adjust the position of the eye shield to suit various work piece Emergency Stop Button In compliance with Australian Standards and ISO 9001, all Brobo grinding/buffing machiens are now provided with emergency STOP button for ease of access during emegency Toolrest As implied, the toolrest provides a stable platform in which the user can rest any toolpiece for resharpening. The height and positon of the toolrest can be moved accordingly via the adjustable bolts provided Water Pot Conveniently located to the machine, water, water-based or oil based lubricants can be placed in the water pot in which the operator can intermittently dip the workpiece in to cool the grinding surface down. Careful note that tools or heavy objects should not be rested in or on the water pot for safety concerns that it might be obstucting the user s access to the emergency stop button. 7

11 3.2 Preparation for Operation The following procedure is recommended for the correct grinding using the Brobo Waldown PG300/350 Pedestal Grinder. PROCEDURE i) Clean the workpiece to ensure it is free of any grit, swarf or flammable substances. It is highly recommended that a solvent be used to remove any residue, while ensuring the solvent is inflammable and non-toxic. ii) iii) iv) Prior to grinding, clear the work area around the work piece of any sizeable items and tools to minimise the likelihood of the user getting injured during the grinding operation. Using the toolrest as a guide, rest the workpiece on the toolrest and manoeuvre it to the desired grinding position. Check that the safety eye shield is directly positioned to deflect swarf and any dislodged particles. v) Turn the machine on. Proceed by slowly easing the workpiece into the grinding wheel. Apply a steady, even pressure and feed downward towards the wheel. vi) Once completed, turn the machine off by depressing the stop button. 3.3 Operation Recommendations To reduce the amount of frictional heat generated between the grinding wheel and workpiece, a light coating of oil or lubricant can be applied onto the workpiece periodically. Do not force the workpiece to the grinding/buffing as this not only significantly reduces the lifespan of the wheel, the workpiece could recoil sharply backwards and injure the operator.. 8

12 CHAPTER 4 - Drawings, Layouts, Assembly and Spare Parts Assembly Drawing (Sheet 1 of 3) 9

13 4.1.2 Assembly Drawing (Sheet 2 of 3) 10

14 4.1.3 Assembly Drawing (Sheet 3 of 3) 11

15 4.1.4 Miscellaneous Part List Please find below of most commonly replaced spare parts, aside from those specified on pages These listed parts draw reference to components found predominantly associated with the Brobo Waldown PG300/350 Pedestal Grinder units. Should you require a spare part that you are not familiar with, or not shown in Chapter 4, please contact Brobo Group Engineering department. PART NUMBER SPARE PART DESCRIPTION ISOLATION SWITCH KIT EYESHIELD MOUNTING BRACKET & GLASS (2 units required) REPLACEMENT EYE SHIELD GLASS (200mm x 150mm) L.H TAPERED BUFF ADAPTOR (1 1/4 x 7 TPI) R.H TAPERED BUFF ADAPTOR (1 1/4 x 7 TPI) L.H TAPERED BUFF ADAPTOR (1 1/2 x 6 TPI) R.H TAPERED BUFF ADAPTOR (1 1/2 x 6 TPI) 12

16 CHAPTER 5 Maintenance and Selection of Consumables 5.1 Role of the Operator The person operating and maintaining the Brobo Waldown PG300/350 Pedestal Grinder must familiarise themselves with these instructions for their own safety and that of others, in addition to safeguarding the production of the machine. Responsibility must be taken by the user on the general maintenance and up keeping of the unit as specified in this chapter, with particular emphasis on: Check to ensure that other operators of the machine always aware of and comply with the relevant safety instructions and standards as specified in Chapter 2 - Safety and Accident Prevention. Therefore, check that the safety devices are operational and work perfectly and that personal safety requirements are complied with. Ensure that the working cycle is efficient and guarantees maximum productivity, inspect the: - Functions of the main components of the machine - Grade of grit on the grinding wheel - Correct working parameters for the type of material being grounded Verify that the quality of each ground material meets the requirements and that the final product is free from any machining defects. 5.2 Maintenance Requirements All maintenance must be carried out with the power switched off and the machine in emergency stop condition. To guarantee perfection operation, all spare parts must be Brobo Group originals. On completion of maintenance works, ensure that the replaced parts or any tools used have been removed from the machines before starting it up. Any behaviour not in accordance with the instructions for using the machine specified in this manual may create hazards and/or safety risks for the operator. Therefore, read and follow all the instructions for use and maintenance of the machine and those on the product itself. 5.3 General Maintenance of Functioning Components The general maintenance operations that should be carried out regularly are as follows: i) Keep the area around the grinder free of any tools, loose parts, accumulated swarf and small offcuts by using compressed air or preferably thread-free cloth. ii) iii) When applicable, lightly lubricate the spindle shaft bearings with an NLGI 2 extreme pressure grease, Shell Alvania No.1 grease or equivalent. Check that the clamping nut and counter plate regularly to ensure its in good condition. Do not over tighten the nut and counter plate, as this will inadvertently exert tension on the spindle and grinding wheel. 13

17 iv) Clean and lubricate any moving joints or sliding surfaces with good quality oil. v) Clean the grinding machine regularly and keep any unpainted surfaces lightly oiled to protect from rust and corrosion. vi) Check that the glass eye shield is in good condition and free of any damage. If a crack is present on the surface of the glass, immediately replace the eye shield by contacting the Brobo Spare Parts Department. 14

18 CHAPTER 6 - Troubleshoot 6.1 General Troubleshooting Below lists of some of the most common problems associated with the Brobo Waldown PG300/350 Pedestal Grinder and the recommended troubleshooting procedures to undertake to rectify the situation. If the solutions provided do not resolve the problems, or the problem identified differs from those listed, immediately contact Brobo Group engineering department. PROBLEM IDENTIFIED DIAGNOSIS SOLUTIONS Excessive consumption of grinding wheel/cracking of grinding wheel Incorrect grade of grit on grinding wheel for parent material Verify that the correct grade of grinding is suited for the parent material being ground. Excessively feed rate, forcing the parent material onto the grinding wheel Reduce the feed rate onto the grinder, else it might cause the parent material to break and cause harm to the operator. Cracking due to sudden force onto grinding wheel ( jarring of grinding wheel) Do not abruptly force the parent material onto the grinding wheel. Instead, the material should be fed onto the grinding wheel at a steady but constant rate. Minimal material removed on the parent part when fed onto the grinder wheel Clogged or worn grinding wheel Incorrect grade of grit on grinding wheel for parent material Replace the grinding wheel. Verify that the correct grade of grinding is suited for the parent material being ground. Machine would not operate Broken or worn component All components to the grinder are sold as spare parts (pending availability). Please contact your nearest Brobo distributor or our Brobo Group head office. Please visit for more details. Electrical component worn All electrical components to the grinder are sold as spare parts (pending availability). Please contact your Brobo distributor. Please also visit for more details. 15

19 BROBO WALDOWN (AUST) PTY. LTD. 8 Fowler Rd, Dandenong, 3175 PO BOX 4274 Dandenong Sth, 3164 Victoria, AUSTRALIA. A.C.N A.B.N Tel: info@brobo.com.au Fax: Website: Quality Endorsed Company ISO 9001 Lic Standards Australia Quality System APPENDIX - RISK/HAZARD ASSESSMENT Hazard Type Hazard Identification Hazard Assessment Hazard Management Strategies (Recommended for the Purchasing / Buyer / User) Cutting/Severing Med/High Mechanical Entanglement Low Impact Low Electrical Electrocution Low Noise - Low Keep machine correctly guarded and operational at all times. Keep hands clear of rotating spindle/grinding wheel. Do not wear loose jewellery, clothing or items that might get caught in the grinder. Always keep the work area free of unnecessary objects or tools. Wear protective safety glasses when utilising the grinding machine. Strongly encouraged that steel-capped safety boots be worn during operation of grinder machine. Remove the power supply when any maintenance and/or repairs are to be undertaken. Power source is to be isolated prior to opening electrical enclosures. Under no load testing, the noise level measured is below 80db (A). If the noise level becomes too high during a grinding cycle, stop the process and inspect for problem, if any are present. Substance - Low Keep the work area clean and regularly remove excess coolant, oils and other aggregate. Hazardous Events Unexpected Start Up Low During a power failure, turn the machine off. If problem persists, please contact Brobo Group engineering department. Additional Hazards Operator Error Low Ensure grinder wheel, counter plates and locking nuts are correctly secured. MACHINE TYPE: SERIAL NO.: RECEVING COMPANY: (SAFETY OFFICER) 16

20 Brobo Group Warranty 1.1 The supplier warrants that all goods supplied by it, shall be free from defects in materials and workmanship for a period of twenty four (24) months from the date of delivery to the Customer. ("the Warranty Period"), on the following terms and conditions. 1.2 The Customer shall promptly provide written particulars to the supplier on becoming aware of any defect in the goods during the Warranty Period, and shall provide the Supplier with all necessary access, facilities and information to enable the Supplier to ascertain or verify the nature and the cause of the defect and to carry out its obligations under this warranty. 1.3 The Supplier's obligation under this warranty is limited to repairs of the defect goods and the Supplier is under no obligation to replace the goods or refund the value of the goods to the Customer. 1.4 If the goods are, in the opinion of the Supplier, not defective or if any defect is attributable to any one or more of the following circumstances then the Supplier is under no obligation whatsoever to the Customer: The use of the goods for a purpose other than that for which they were intended to be used; The repair, modification or alteration of the goods by any person other than the Supplier; Where the defect has arisen due to misuse, neglect or accident, howsoever arising; Where the defect has arisen due to installation of the goods which were, in the reasonable opinion of the Supplier, incorrectly carried out Where the goods have not been correctly stored or maintained Where the defect has arisen due to normal wear and tear on the goods 1.5 The Supplier is under no obligation under this warranty where the Customer has failed to observe the terms of payment for the goods or any other obligation imposed by the terms and conditions of this warranty. 1.6 In the event that the Supplier is supplying goods, which have been manufactured by third parties, the Customer shall be entitled to the benefit of any Manufacturer's Warranty in respect of such goods. The Customer acknowledges that the Supplier accepts no responsibility whatsoever for any Manufacturer's Warranty or any claim howsoever arising from the use of the goods, whether singularly or in combination with other products. 1.7 The Supplier shall not be liable for any indirect or consequential losses or expenses suffered by the Customer, howsoever caused. 1.8 Except as specifically set out herein, or in writing by way of catalogue or pamphlet or otherwise provided by the Supplier to the Customer any term, representation, condition or warranty in respect of the quality, condition or description of the goods, whether implied by statute, common law, trade usage, custom or otherwise, is hereby expressly excluded. This warranty is given by Brobo Group Pty Ltd, ABN: Address: Williams Rd, Dandenong, VIC 3175 Ph: Fax: info@brobo.com.au This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.